Multi-layered food product and method for forming

ABSTRACT

A multi-layered food product comprises a filling encapsulated by a substantially baked yeast-leavened dough. The encapsulated filling is further encapsulated by a substantially baked chemically-leavened batter layer.

RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 12/958,313, filed Dec. 1, 2010, which claims priority from U.S.Provisional Application Ser. No. 61/265,457, filed Dec. 1, 2009. Theentirety of each of the aforementioned applications is herebyincorporated by reference.

TECHNICAL FIELD

The claimed subject matter relates generally to filled food products,and more particularly to a multi-layered food product and method forforming the multi-layered food product.

BACKGROUND OF THE INVENTION

Demand for convenience food has steadily increased in recent years. Aspeople look to find ways to maximize free time, ready-made meals andsnack products have become increasingly popular with consumers. Mosthouseholds now have a microwave oven to assist in the rapid heating offood. Accordingly, a large number of ready-made meals and snacks havebeen developed which can be heated in a microwave oven.

While these types of snacks and meals can be quickly heated in amicrowave oven, the types of meals and snacks that are suitable forheating in such ovens are, to some extent, limited. For example, snacksof a type which have a filling surrounded by a crispy coating typicallycannot be satisfactorily prepared in a microwave oven. This is becausesteam, generated during the heating process by evaporation of water fromthe filling, is deleterious to organoleptic qualities of the coating.Steam penetrates the outer coating rendering it moist, soggy andunappetizing. Such crispy-coated products are typically best prepared byheating in a conventional oven, or frying in oil to maintain crispness.This considerably lengthens the time required to prepare such snacks,thus making them far less convenient to prepare.

SUMMARY OF THE INVENTION

According to one aspect of the claimed subject matter, a multi-layeredfood product comprises a filling encapsulated by a substantially bakedyeast-leavened dough. The encapsulated filling is further encapsulatedby a substantially baked chemically-leavened batter layer.

According to another aspect of the claimed subject matter, a method isprovided for forming a multi-layered food product. One act of the methodincludes substantially baking an insert in a first bi-molded plateassembly. The insert comprises a filling that is completely enveloped bya yeast-leavened dough. Next, the substantially baked insert is placedinto a second bi-molded plate assembly so that the substantially bakedinsert is located atop a first amount of a chemically-leavened batterlayer. A second amount of the chemically-leavened batter is then pouredinto the second bi-molded plate assembly so that the second amount ofthe chemically-leavened batter substantially or completely envelops thesubstantially baked insert. The second bi-molded plate assembly isheated for a time and at a temperature sufficient to bake themulti-layered food product.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features of the claimed subject matter willbecome apparent upon reading the following description with reference tothe accompanying drawings, in which:

FIG. 1A is a perspective view of a multi-layered food product inaccordance with one aspect of the claimed subject matter;

FIG. 1B is a cross-sectional view taken along Line 1B-1B in FIG. 1A;

FIG. 2A is a perspective view of a multi-layered food product inaccordance with another aspect of the claimed subject matter;

FIG. 2B is a cross-sectional view taken along Line 2B-2B in FIG. 2A;

FIG. 2C is a perspective view of a substantially baked insert comprisinga portion of the multi-layered food product in FIGS. 2A-B;

FIG. 2D is a cross-sectional view taken along Line 2D-2D in FIG. 2C;

FIG. 3A is a perspective view of a multi-layered food product inaccordance with another aspect of the claimed subject matter;

FIG. 3B is a cross-sectional view taken along Line 3B-3B in FIG. 3A;

FIG. 4 is a process flow diagram illustrating a method for forming amulti-layered food product according to another aspect of the claimedsubject matter;

FIG. 5 is a schematic diagram showing an automated assembly line systemused to form the multi-layered food product of the claimed subjectmatter;

FIG. 6 is a schematic diagram showing an alternative configuration ofthe automated assembly line system in FIG. 5;

FIG. 7A is a perspective view of a first bi-molded plate assembly forforming the substantially baked insert in FIGS. 2A-D;

FIG. 7B is a top view of a second baking plate of the first bi-moldedplate assembly in FIG. 7A;

FIG. 8A is a perspective view of a second bi-molded plate assembly forforming the multi-layered food product in FIGS. 1A-2D, the secondbi-molded plate assembly comprising a lid member and a receptaclemember;

FIG. 8B is a side view of the second bi-molded plate assembly in FIG.8A;

FIG. 9A is a side view of the lid member shown in FIG. 8A;

FIG. 9B is a top view of the lid member shown in FIG. 9A;

FIG. 10A is a side view of the receptacle member shown in FIG. 8A;

FIG. 10B is a top view of the receptacle member shown in FIG. 10A;

FIG. 11 is a process flow diagram illustrating a further aspect of themethod shown in FIG. 4;

FIG. 12 is a process flow diagram illustrating a method for forming amulti-layered food product according to another aspect of the claimedsubject matter; and

FIG. 13 is a schematic diagram showing an alternative configuration ofthe automated assembly line system in FIG. 6.

DETAILED DESCRIPTION

The claimed subject matter relates generally to filled food products,and more particularly to a multi-layered food product and method forforming the multi-layered food product. As representative of one aspectof the claimed subject matter, FIGS. 1A-2D illustrates a multi-layeredfood product 10 or 10′ that combines the strength and functionality ofyeast-leavened bread with the delicate eating quality of a quick breador cake. Unlike conventional filled food products, the multi-layeredfood product 10 or 10′ of the claimed subject matter combines ayeast-leavened dough insert 12 or 12′, which provides structuralintegrity to the product to facilitate eating by hand, with achemically-leavened batter 14 that gives the product a soft andappealing eating quality, which is absent in purely yeast-leavened breadproducts. Additionally, the multi-layered food product 10 or 10′ can beinitially warmed in a microwave and then reconstituted in an oven ortoaster to yield a food product having a crispy exterior and a softinterior without the chewy or tough consistency of a typicalyeast-leavened bread product.

The multi-layered food product 10 or 10′ has a molded configuration(e.g., puck-shaped) and a partially uniform color. Although apuck-shaped configuration is shown, the multi-layered food product 10 or10′ can have other shapes, such as rectangular, circular, ovoid, square,triangular, cylindrical, star-shaped, or any other polygonal shape. Thepartially uniform color gives the multi-layered food product 10 or 10′the appearance of a home-baked meal or snack that has been prepared on agriddle, pan or Panini. Although the multi-layered food product 10 or10′ is shown as having a puck-shaped configuration, it will beappreciated that the product can have any desirable shape and size thatmakes the product versatile and easy to consume. For example, themulti-layered food product 10 or 10′ can have any shape and size thatenables a consumer to easily eat the multi-layered food product at homeor on-the-go without any mess. The molded configuration of themulti-layered food product 10 or 10′ also allows the product to bequickly and easily reconstituted for consumption in a microwave and/ortoaster, or simply by oven.

As shown in FIG. 1B, the multi-layered food product 10 comprises asubstantially baked insert 12 or 12′ that includes a filling 16, whichis substantially (e.g., more than 50%, about 60%, about 70%, about 80%or about 90%) or completely enveloped or encapsulated by ayeast-leavened dough 18. The substantially baked insert 12 or 12′ issubstantially or completely enveloped or encapsulated by achemically-leavened batter layer 14. The substantially baked insert 12or 12′ has a molded configuration (e.g., a puck-like shape). As notedabove, the substantially baked insert 12 or 12′ additionally includes afilling 16 that is substantially or completely enveloped or encapsulatedby the yeast-leavened dough 18. The filling 16 can comprise any desiredsolid or semi-solid food product that is typically included as part of ameal or snack. Examples of fillings 16 can include fruit, cheese, eggs,meat (e.g., ham, bacon, sausage, hamburger, chicken, turkey, etc.),vegetables, sauces, and/or a combination thereof.

The multi-layered food product 10 or 10′ combines the distinctivestructural and taste characteristics of yeast- and chemically-leavenedbreads into a single food product. Yeast-leavened breads usefermentation to create carbon dioxide “bubbles” and thereby leaven thedough. Fermentation begins by mixing the ingredients together to developa strong gluten structure, which allows the dough to accumulate carbondioxide. Leavening continues to occur in the proofing stage, in which alow heat and high humidity environment promotes optimal yeastfermentation. Yeast leavening is highly regarded as contributingdesirable tastes and aromas to bread. For example, yeast-leavened breadstend to have a smooth outer crust and airy, flaky interiors.

Chemically-leavened breads, also known as “quick breads”, are formed bythe reaction of bicarbonate compounds with acid-reactive ingredients.Sodium bicarbonate is the most commonly used chemical leavening agent,but potassium and ammonium bicarbonates are also used. Chemicalleavening typically occurs in two stages. The first stage releasescarbon dioxide during mixing, while the second stage releases carbondioxide during the baking process by the activation of certain chemicalleavening ingredients. One advantage of chemical leavening is the quickformation of carbon dioxide bubbles within a dough or batter mixture,without the need for proofing. Unlike yeast-leavened breads, quickbreads are known for having a slightly coarse texture and soft crusts.

The weight-percent (wt-%) of the chemically-leavened batter 14, thefilling 16, and the yeast-leavened dough 18 can be varied to impart themulti-layered food product 10 or 10′ with desired structural and tastecharacteristics. In one example of the present invention, the wt-% ofthe filling 16 can be about 15% to about 60% of the total weight of themulti-layered food product 10 or 10′, the wt-% of the yeast-leaveneddough 18 can be about 10% to about 60% of the total weight of themulti-layered food product, and the wt-% of the chemically-leavenedbatter layer 14 can be about 15% to about 60% of the total weight of themulti-layered food product.

The leavening agents and/or other ingredients used to form thechemically-leavened batter layer 14 and the yeast-leavened dough 18 canalso be varied depending upon the particular structural and tastecharacteristics of the multi-layered food product 10 or 10′. Forexample, the wt-% of yeast to flour in the yeast-leavened dough 18 canbe about 1% to about 6%. Additionally, one or a combination of chemicalleavening agents (e.g., baking powder) can be used to form thechemically-leavened batter layer 14. For example, the wt-% of thechemical leavening agent (e.g., baking powder) to flour in thechemically-leavened batter layer 14 can be about 0% to about 8%.

FIGS. 2A-D illustrate a multi-layered food product 10′ according toanother aspect of the claimed subject matter. The multi-layered foodproduct 10′ can have a molded configuration (e.g., puck-shaped) and apartially uniform color. Although the multi-layered food product 10′ isshown as having a puck-shaped configuration, it will be appreciated thatthe product can have any desirable shape and size that makes the productversatile and easy to consume.

As shown in FIGS. 2A-D, the substantially baked insert 12′ has a moldedconfiguration and is defined by oppositely disposed first and secondmajor surfaces 20 and 22. At least one of the first and second majorsurfaces 20 and 22 can include a finger member 24 that projectsoutwardly from at least one of the first and second major surfaces. Asshown in FIG. 2C, for example, each of the first and second majorsurfaces 20 and 22 can include a plurality of finger members 24. Thefinger members 24 generally serve to secure the substantially bakedinsert 12′ within the chemically-leavened batter layer 14 and preventthe insert from “sinking” to either side of the multi-layered foodproduct 10′. It should be appreciated that, where desired, the firstand/or second major surfaces 20 and 22 may not include any fingermembers 24.

The finger members 24 are formed from the yeast-leavened dough 18 andare dispersed about the first and second major surfaces 20 and 22. Thefinger members 24 can be dimensioned (e.g., have a sufficient height,width, and thickness) to keep the substantially baked insert 12′ fromsinking to either side of the multi-layered food product 10′. The fingermembers 24 may or may not be visible about the multi-layered foodproduct 10′. The finger members 24 can be symmetrically orasymmetrically dispersed about the first major surface 20 and/or thesecond major surface 22. The finger members 24 can have any desiredshape or configuration, such as the dome-shaped configuration shown inFIG. 2C. Although not shown, it will be appreciated that one or more ofthe finger members 24 can alternatively have a ridge-like configurationthat extends across all or only a portion of the first major surface 20and/or the second major surface 22. FIGS. 3A-B illustrate amulti-layered food product 10″ according to another aspect of theclaimed subject matter. The multi-layered food product 10″ can have amolded configuration (e.g., puck-shaped) and a partially uniform color.Although the multi-layered food product 10″ is shown as having apuck-shaped configuration, it will be appreciated that the product canhave any desirable shape and size that makes the product versatile andeasy to consume. For example, the multi-layered food product 10″ canhave any shape and size that enables a consumer to easily eat themulti-layered food product at home or on-the-go without any mess. Themolded configuration of the multi-layered food product 10″ also allowsthe product to be quickly and easily reconstituted for consumption in amicrowave and/or toaster, or simply an oven.

As shown in FIG. 3B, the multi-layered food product 10″ can comprise ainsert 12″ including a filling 16 that is substantially or completelyenveloped or encapsulated by a yeast-leavened dough 18. As describedabove, the filling 16 can include any desired solid or semi-solid foodproduct that is typically included as part of a meal (e.g., fruit,cheese, eggs, meat, vegetables, sauces, and/or a combination thereof) orsnack.

The weight-percent (wt-%) of the filling 16 and the yeast-leavened dough18 can be varied to impart the multi-layered food product 10″ withdesired structural and taste characteristics. In one example of thepresent invention, the wt-% of the filling 16 can be about 25% to about75% of the total weight of the multi-layered food product 10″, and thewt-% of the yeast-leavened dough 18 can be about 25% to about 75% of thetotal weight of the multi-layered food product.

As illustrated in FIGS. 4-6 and 13, another aspect of the claimedsubject matter includes a method 30 for forming a multi-layered foodproduct 10 or 10′. The method 30 can be performed using an automatedassembly line system (FIGS. 5-6 and 13) comprising first and secondautomated assembly lines 50 and 52 (and 206). The first automatedassembly line 50 is for preparing the substantially baked insert 12 or12′ and comprises a series of upper and lower loop-shaped tracts 54 and56, a portion of each of which is disposed within an oven 58. The upperand lower tracts 54 and 56 of the first automated assembly line 50include a plurality of first baking plates 60 securely mounted theretothat can be securely mated together to form a plurality of firstbi-molded plate assemblies 62 (FIGS. 7A-B).

As shown in FIGS. 7A-B, each of the first bi-molded plate assemblies 62formed by each of the first baking plates 60 have a puck- or disc-shapedconfiguration and form a cavity 64 therebetween. The cavity 64 isdefined by first and second plates 66 and 68. The dimensions (e.g.,height, width, length, cavity depth, etc.) of the first and secondplates 66 and 68 can be about equal so that the dimensions of thesubstantially baked insert 12 or 12′ formed by the method 30 are alsoabout equal. An inner surface 70 of each of the first and second plates66 and 68 can include at least one depression 72 for forming the fingermembers 24. For example, each of the depressions 72 can have adome-shaped configuration for producing finger members 24 having aconfiguration as shown in FIGS. 2A-D. It will be appreciated that thedepressions 72 can have any configuration for forming finger members 24with any corresponding desired configuration. All or only a portion ofeach of the first bi-molded plate assemblies 62 can be made of a rigid,heat-conductive material (e.g., a metal or metal alloy).

As shown in FIG. 5, the second automated assembly line 52 is forpreparing the multi-layered food product 10 or 10′ and comprises acontinuous, loop-shaped tract 74 having an upper portion 76 and a lowerportion 78. A portion of the second assembly line 52 is seated within anoven 80. The tract 74 of the second assembly line 52 is operably matedto opposing rotation members 82, each of which is separately or jointlypowered by a power source (not shown). As described in greater detailbelow, the second assembly line 52 also includes an automatic removingsystem 84, a first batter injector 86, an insert feeding system 88, anda second batter injector 90.

The second assembly line 52 also includes a plurality of second bakingplates 92, each of which includes at least one of a second bi-moldedplate assembly 94 (FIGS. 8A-B). As shown in FIG. 5, the second assemblyline 52 includes fourteen second baking plates 92 having six of thesecond bi-molded plate assemblies 94 in each. It will be appreciatedthat the number of the second baking plates 92, as well as the number ofthe second bi-molded plate assemblies 94 comprising each of the secondbaking plates can be varied depending upon production needs and theconfiguration of the second assembly line 52.

As shown in FIGS. 8A-B, the second bi-molded plate assemblies 94comprises a receptacle member 96 and a lid member 98. All or only aportion of each of the second bi-molded plate assemblies 94 can be madeof a rigid, heat-conductive material (e.g., a metal or metal alloy). Thereceptacle member 96 and the lid member 98 each have a generallycircular or oval-shaped configuration and include a cavity 100 (FIGS. 9Aand 10A). When the receptacle member 96 (FIG. 8B) and the lid member 98are securely mated with one another, the cavities 100 of the lid memberand the receptacle member form a molded baking cavity 102. The moldedbaking cavity 102 can have a diameter of about 6 cm to about 15 cm, anda depth of about 1 cm to about 5 cm.

The molded baking cavity 102 is designed to hold and bake the componentsof the multi-layered food product 10 or 10′ concurrently. Accordingly,the flavor of the multi-layered food product 10 or 10′ is enhancedthrough the process of baking the product components within the moldedbaking cavity 102. In addition to the leavening power that themulti-layered food product 10 or 10′ receives from the yeast-leaveneddough 18 and the chemically-leavened batter 14, the multi-layered foodproduct receives further leavening from the steam generated within thesealed molded baking cavity 102 during the baking process.

The lid member 98 (FIG. 9A) of each of the second bi-molded plateassemblies 94 has a disc-like shape and is defined by oppositelydisposed first and second major surfaces 104 and 106. The first majorsurface 104 has a generally smooth, flat configuration that graduallytapers around the edge 108 towards the second major surface 106. Thesecond major surface 106 is adapted for mating with the receptaclemember 96. As shown in FIG. 9A, the cavity 100 of the lid member 98extends from the second major surface 106 towards the first majorsurface 104 such that the cavity is recessed within the second majorsurface. The cavity 100 of the lid member 98 defines a volume capable ofholding between about 0% and about 40% of the multi-layered food product10 or 10′ during the baking process.

As shown in FIGS. 10A-B, the receptacle member 96 has a rounded,pan-shaped configuration. The receptacle member 96 includes oppositelydisposed first and second major surfaces 110 and 112 and an annular sidewall 114 that extends between the first and second major surfaces. Thecavity 100 of the receptacle member 96 extends between the first majorsurface 110 and the bottom surface 116 of the receptacle member. Thecavity 100 of the receptacle member 96 defines a volume that is greaterthan the volume of the lid member 98. The cavity 100 of the receptaclemember 96 is capable of holding between about 60% and about 100% of themulti-layered food product 10 or 10′ during the baking process.

It will be appreciated that one or more of the second bi-molded plateassemblies 94 can include an imprinting surface (not shown in detail)for imparting all or only a portion of a surface of the multi-layeredfood product 10 or 10′ with a decorative design. For example, one ormore surfaces defining the cavity 100 of the second bi-molded plateassembly 94 can include at least one depressed and/or raised imprintingsurface having a decorative or aesthetically pleasing design. Theimprinting surface may additionally or optionally serve to securelypositioning the substantially baked insert 12 or 12′ during baking. Forexample, the imprinting surface may assist in maintaining thesubstantially baked insert 12 or 12′ proportionally in the center of thecavity 100 during baking.

At Act 32, the method 30 can begin by heating the first baking plates 60to a predetermined temperature (e.g., about 250° F. to about 450 F.).Either prior to, contemporaneous with, or subsequent to Act 32, the rawcomponents of the multi-layered food product 10 or 10′ are prepared. Forexample, the yeast-leavened dough 18 can be formed by scaling (e.g.,measuring out) the needed ingredients, which may include flour (e.g.,about 27% to about 68% of the total batch weight), water (e.g., about21% to about 57% of the total batch weight), milk powder (e.g., about 0%to about 9% of the total batch weight), eggs (e.g., about 2% to about15% of the total batch weight), gluten (e.g., about 2% to about 5% ofthe total batch weight), sugar (e.g., about 2% to about 15% of the totalbatch weight), oil (e.g., about 0% to 15% of the total batch weight),yeast (e.g., about 1% to about 5% of the total batch weight), and salt(e.g., about 0.5% to about 2% of the total batch weight).

It will be appreciated that other ingredients may be added to adjust theflavor or improve the functionality of the yeast-leavened dough 18.Examples of ingredients that can be added to adjust the flavor of theyeast-leavened dough 18 can include butter, cheese, spices, naturalflavorings, and fruit or nut inclusions. Examples of ingredients thatmay be added to improve the functionality of the yeast-leavened dough 18can include baking enzymes, monoglycerides, fats and oils. After theingredients are scaled, the ingredients are then mixed and kneadedtogether for a period of time sufficient to develop the gluten structureof the yeast-leavened dough 18. The fully developed, yeast-leaveneddough 18 is then ready for subsequent use.

After preparing the yeast-leavened dough 18, a measured amount of one ormore fillings 16 is “encrusted” inside a measured amount of theyeast-leavened dough to form the insert 12 or 12′. The measured amountof filling 16 may range from about 15 grams to about 99 grams, and themeasured amount of the yeast-leavened dough 18 may range from 12 gramsto about 128 grams. After the filling 16 is encrusted inside theyeast-leavened dough 18, the formed product comprises a ball-shapedinsert 12 or 12′ that is substantially or completely enveloped by theyeast-leavened dough and includes the filling at its center.

The insert 12 or 12′ can be passed through a molding or shaping device(not shown) so that upper and/or lower portions of the insert arepartially flattened. The molded insert 12 or 12′ is placed into a bakeryproofing chamber 118 (FIG. 5) for a period of time sufficient toadequately “rise” or “proof” the insert prior to baking. For example,the proofing time can vary from about 10 minutes to about 60 minutes,depending upon the type and size of the yeast-leavened dough 18 and thefilling 16. After the insert 12 or 12′ is adequately proofed, it isready for subsequent use.

Either before, during, or after formation of the insert 12 or 12′, thechemically-leavened batter layer 14 is prepared. Creation of thechemically-leavened batter layer 14 begins by scaling the necessaryingredients, which may include water (e.g., about 29% to about 68% ofthe total batch weight), flour (e.g., about 15% to about 40% of thetotal batch weight), eggs (e.g., about 5% to about 30% of the totalbatch weight), sugar (e.g., about 0% to about 17% of the total batchweight), milk powder (e.g., about 0% to about 12% of the total batchweight), oil (e.g., about 0% to about 15% of the total batch weight),baking powder (e.g., about 0.5% to about 5% of the total batch weight),baking soda (e.g., about 0% to about 2% of the total batch weight), andsalt (e.g., about 0.5% to about 3% of the total batch weight).

It will be appreciated that other ingredients may be added to adjust theflavor or improve the functionality of the chemically-leavened batterlayer 14. Examples of ingredients that may be added to adjust the flavorof the chemically-leavened batter layer 14 may include butter, cheese,meat, natural flavors or spices, fruits, nuts, and the like. Examples ofingredients that may be added to improve the functionality of thechemically-leavened batter layer 14 may include oils, fats, emulsifiers,and the like.

After scaling the desired ingredients, the ingredients are thenthoroughly mixed until they are adequately combined into a partiallyliquid form, typically in a large temperature-controlled stirring vat(not shown). The mixed ingredients may then be transferred to a secondbatter mixer (not shown) where additional ingredients can be added(e.g., eggs), stirred at high speeds, and properly aerated. Theresultant chemically-leavened batter layer 14 may then be placed insidea temperature-controlled container (e.g., first and second batterinjectors 86 and 90) that will be used to deposit thechemically-leavened batter during the baking process.

Prior to, simultaneous with, or subsequent to preparation of the insert12 or 12′ and the chemically-leavened batter 14, the insert can besubstantially baked at Act 34. As shown in FIG. 5, an insert 12 is takenfrom the proofing chamber 118 and deposited into a first baking plate 60(e.g., the second plate 68 of a first bi-molded plate assembly 62). Itwill be appreciated that the insert 12 or 12′ can be deposited into thefirst baking plate 60 by any one or combination of suitable mechanisms,such as via a robotic arm, conveyor belt system 140 (FIG. 6), or byhand. Once the insert 12 or 12′ is deposited into the first baking plate60, the baking plate rotates about the lower tract to securely mate withanother baking plate, thereby forming a plurality of first bi-moldedplate assemblies 62.

The baking plates 60 then move through an oven 58 (e.g., a tunnel oven)for a time and at a temperature sufficient to substantially bake theinsert 12 or 12′. In some instances, the term “substantially baked” canmean that the insert 12 or 12′ is baked about 80%, about 85%, about 90%,about 95% or 100% (completely baked). In other instances, the term“substantially baked” can mean par baked. In one example, par baked canmean baked less than 100% at a first time, and then subsequentlycompletely baked at a different second time. In further instances, theterm “substantially baked” can mean baked less than 100%, but more than80%.

For example, the first baking plates 60 can move through oven 58 so thatthe insert 12 or 12′ is completely or 100% baked and, thus, free fromliquid or moisture. For instance, the first baking plates 60 can movethrough oven 58 for a time of about 20 seconds to about 90 seconds andat a temperature of about 250° F. to about 450° F. to substantially orcompletely bake the insert 12 or 12′.

After the first baking plates 60 pass through the oven 58, the bakingplates are separated as shown in FIG. 5 so that the substantially bakedinsert 12 or 12′ can be removed from the plates and deposited into theinsert feeding system 88. It will be appreciated that the substantiallybaked insert 12 or 12′ produced by the method 30 can be deposited intothe insert feeding system 88 by any one or combination of mechanisms,such as a transfer machine 142 (FIG. 6) that removes the substantiallybaked insert 12 or 12′ from the first baking plates 60 and then passesthe insert onto a conveyor belt system 140. Prior to depositing thesubstantially baked insert 12 or 12′ into the insert feeding system 88,the second baking plates 92 (and thus each of the second bi-molded plateassemblies 94) are heated to a predetermined temperature (e.g., about300° F. to about 450° F.) at Act 36. Upon heating each of the secondbi-molded plate assemblies 94 to the predetermined temperature andforming the components of the multi-layered food product 10 or 10′, thesecond assembly line 52 is activated so that the tract 74 progressivelymoves in a clock-wise motion at a predetermined rate.

At Act 38, the first batter injector 86 is operated to pour a firstamount of the chemically-leavened batter layer 14 into the cavity 100 ofeach of the receptacle members 96. The first amount of thechemically-leavened batter layer 14 is delivered in an amount sufficientto cover at least a substantial portion of the bottom surface 116 ofeach of the receptacle members 96. The total amount of thechemically-leavened batter layer 14 that is poured into the receptaclemembers 96 can vary between about 10 grams and about 128 grams,depending upon the type of multi-layered food product 10 or 10′ beingmade. It will be appreciated that a pan release agent (e.g., baking oil)can be applied to all or only a portion of the molded baking cavity 102prior to the addition of the raw components to prevent or mitigatesticking.

At Act 40, the second baking plates 92 are advanced along the secondassembly line 52 to the insert feeding system 88. The insert system 88is then activated to place a substantially baked insert 12 or 12′ atopthe first amount of the chemically-leavened batter layer 14 already ineach of the receptacle members 96. The substantially baked insert 12 or12′ is placed atop the first amount of the chemically-leavened batterlayer 14 so that no portion of the insert comes into contact with eachof the receptacle members 96. In other words, a substantially bakedinsert 12 or 12′ is placed in each of the receptacle members 96 so thateach insert is at least partially enveloped or encapsulated by the firstamount of the chemically-leavened batter layer 14. The volume of each ofthe receptacle members 96 filled by the first amount of thechemically-leavened batter layer 14 and the substantially baked insert12 or 12′ can be from about 35% to about 75%.

As the second baking plates 92 continue to advance along the secondassembly line 52, the second batter injector 90 is operated to pour asecond amount of the chemically-leavened batter layer 14 into each ofthe receptacle members 96 (Act 42). The second amount of thechemically-leavened batter layer 14 is delivered in an amount sufficientto fill an additional 20% to about 65% of the cavity 100 of each of thereceptacle members 96. Importantly, the second amount of thechemically-leavened batter layer 14 is poured into each of thereceptacle members 96 such that each of the substantially baked inserts12 or 12′ is substantially or completely enveloped by thechemically-leavened batter layer.

At Act 44, each of the second bi-molded plate assemblies 94 is arrangedto form the molded baking cavity 102. For example, the second majorsurface 106 of each of the lid members 98 is securely mated with thefirst major surface 110 of each of the receptacle members 96 to form aheated and sealed molded baking cavity 102. By “sealed” it is understoodthat the baking cavity 102 can include holes, vents, or other aperturesthat permit the release of steam from the baking cavity while preventingleakage of product components. It will be appreciated that Acts 36-44 ofthe method 30 plus a first baking period are conducted during a firstperiod of time (Act 46), which is about 10% to about 40% of the totaltime required to bake the multi-layered food product 10 or 10′.

After assembling the molded baking cavities 102 and then baking for thefirst period of time, the second baking plates 92 are rotated about therotation members 82 (indicated by arrows) so that the second bi-moldedplate assemblies 94 is inverted (Act 120) (FIG. 11). Inverting thesecond bi-molded plate assemblies 94 allows the chemically-leavenedbatter layer 14 to distribute better within each of the molded bakingcavities 102, while also facilitating more even baking throughout themulti-layered food product 10 or 10′. After inverting the second bakingplates 92, the second baking plates are heated for a second period oftime, which is greater than the first period of time (Act 122). Forexample, the second period of time can be about 60% to about 90% of thetotal time needed to bake the multi-layered food product 10 or 10′. Bybaking components (e.g., all of the components) of the multi-layeredfood product 10 under pressure and at a uniform temperature, theyeast-leavened dough 18 and the chemically-leavened batter layer 14 canbe combined to form a substantially seamless, borderless product.

At Act 48 (FIG. 4), the automatic removing system 84 separates the lidmember 98 and the receptacle member 96 of each of the second bi-moldedplate assemblies 94 after the multi-layered food product 10 or 10′ hasbeen sufficiently baked. Since each of the receptacle members 96 isinverted, separation of the lid members 98 from the receptacle membersallows the multi-layered food product 10 or 10′ to be easily removedfrom the second bi-molded plate assemblies 94 via gravity.Alternatively, the multi-layer food product 10 or 10′ can be removed bya suction mechanism (not shown) once the bi-molded plate assemblies 94have rotated back around the rotation members 82 and the lid members 98have opened. After removing the multi-layered food product 10 or 10′from each of the bi-molded plate assemblies 94, the multi-layered foodproduct is cooled for an appropriate period of time before freezing,wrapping and packaging. The packaged, multi-layered food product 10 or10′ can be boxed and further frozen ahead of distribution to themarketplace.

As illustrated in FIG. 12, another aspect of the claimed subject matterincludes a method 130 for forming a multi-layered food product 10″. Themethod 130 is similar to the method 30 illustrated in FIG. 4. Forexample, the method 130 can be performed using an automated assemblyline that is identical or similar to the first automated assembly line50 described above. Additionally, the method 130 can be performed usingbi-molded plate assemblies (not shown) that are similar to the firstbi-molded plate assemblies 62 described above. For example, each of thereceptacle members comprising the bi-molded plate assemblies can have avolume that is about the same as the volume of the lid members.

At Act 36, the method 130 can begin by heating the bi-molded plateassemblies to a predetermined temperature (e.g., about 300° F. to about450° F.). Either prior to, contemporaneous with, or subsequent to Act36, the raw components of the multi-layered food product 10″ can beprepared. For example, the yeast-leavened dough 18 can be formed byscaling (e.g., measuring out) the needed ingredients (as describedabove). As also described above, it will be appreciated that otheringredients may be added to adjust the flavor or improve thefunctionality of the yeast-leavened dough 18.

After the ingredients are scaled, the ingredients can then be mixed andkneaded together for a period of time sufficient to develop the glutenstructure of the yeast-leavened dough 18. Next, a measured amount of oneor more fillings 16 can be “encrusted” inside a measured amount of theyeast-leavened dough 18 using a known bakery machining process. Themeasured amount of filling 16 may range from about 15 grams to about 99grams, and the measured amount of the yeast-leavened dough 18 may rangefrom 12 grams to about 128 grams. After the filling 16 is encrustedinside the yeast-leavened dough 18, the formed product comprises aball-shaped insert 12″ that is completely enveloped or encapsulated bythe yeast-leavened dough and includes the filling at its center.

The insert 12″ can be passed through a molding or shaping device (notshown) so that upper and lower portions of the insert are partiallyflattened. The molded insert 12″ is then placed into a bakery proofingchamber 118 for a period of time sufficient to adequately “rise” or“proof” the insert prior to baking. For example, the proofing time canvary from about 10 minutes to about 60 minutes, depending upon the typeand size of the yeast-leavened dough 18 and the filling 16. After theinsert 12″ is adequately proofed, it is ready for subsequent use.

Upon heating each of the bi-molded plate assemblies to the predeterminedtemperature and forming the raw components of the multi-layered foodproduct 10″, the insert 12″ can be placed into a receptacle member of abi-molded plate assembly (Act 132) and the lid member mated with thereceptacle member to form a sealed baking cavity (Act 44).

Following formation of the sealed baking cavity, the insert 12″ can beentirely baked at Act 46. As described above, an insert 12″ is takenfrom the proofing chamber 118 and deposited into the receptacle memberof a bi-molded plate assembly. It will be appreciated that the insert12″ can be deposited into the receptacle member by any one orcombination of mechanisms known in the art, such as via a robotic arm,conveyor belt system 140 (FIG. 6), or by hand. Once the insert 12″ isdeposited into the receptacle member, the receptacle members and the lidmembers rotate about the tracts of an oven 58 (e.g., a tunnel oven) tosecurely mate with another and thereby form a plurality of bi-moldedplate assemblies.

The bi-molded plate assemblies then move through the oven 58 for a timeand at a temperature sufficient to completely bake the insert 12″. Forexample, the bi-molded plate assemblies can move through oven 58 so thatthe insert 12″ is baked to completion (100% baked). For instance, thefirst bi-molded plate assemblies can move through the oven 58 for a timeof about 1 minute to about 4 minutes and at a temperature of about 300°F. to about 450° F. to completely bake the insert 12″.

After the bi-molded plate assemblies pass through the oven 58, thereceptacle members and the lid members are separated as shown in FIG. 5so that the multi-layered food product 10″ can be removed from theplates and cooled for an appropriate period of time before freezing,wrapping and packaging. The packaged, multi-layered food product 10″ canbe boxed and further frozen ahead of distribution to the marketplace.

It will be appreciated that the claimed subject matter can include analternative assembly line system 200 (FIG. 13) for forming amulti-layered food product 10 or 10′. As shown in FIG. 13, the assemblyline system 200 includes a series of upper and lower loop-shaped tracts202 and 204, a portion of each of which is disposed within an oven 206.The upper and lower tracts 202 and 204 include a plurality of bakingplates 208 (not shown in detail) securely mounted thereto that can bemated together to form a plurality of bi-molded plate assemblies (notshown) (as described above). The lower tract 204 has a greater lengththan the upper tract 202, which allows the components of themulti-layered food product 10 or 10′ to be supplied to the baking plates208 as shown in FIG. 13. Other components of the assembly line system200 are similar or identical to those shown in FIG. 6 and describedabove, such as a bakery proofing chamber 212, a conveyor belt system214, a second oven 216, a transfer machine 218, a first batter injector220, an insert feeding system 222, a second batter injector 224, and anoptional automatic removing system 225. For example, the oven 206 isdifferent than the oven 52 described above because there is no inversionor flipping of plates during operation.

In operation, the baking plates are heated to a pre-determinedtemperature (as described above). The first batter injector 220 isoperated to pour a first amount of a chemically-leavened batter layer 14into each of the baking plates 208. The baking plates 208 are thenadvanced along the lower tract 204 (e.g., clockwise) to the insertfeeding system 222, which is activated to place a substantially bakedinsert 12 or 12′ atop the first amount of the chemically-leavened batterlayer 14 already in each of the baking plates 208. As the baking plates208 continue to advance along the lower tract 204, the second batterinjector 224 is operated to pour a second amount of thechemically-leavened batter layer 14 into each of the baking plates (asdescribed above). Once the second amount of the chemically-leavenedbatter layer 14 is deposited into each of the baking plates 208, thebaking plates of the upper tract 202 rotate (e.g., counter-clockwise) tosecurely mate with the baking plates of the lower tract 204, therebyforming the plurality of bi-molded plate assemblies.

Next, the bi-molded plate assemblies move through the oven 206 for atime and at a temperature sufficient to substantially or completely bakethe multi-layered food product 10 or 10′ (as described above). The totalbake time is about 30 seconds to about 200 seconds. After the bi-moldedplate assemblies pass through the oven 206, the baking plates of thelower and upper tracts 204 and 202 are separated so that thesubstantially or completely baked multi-layered food product 10 or 10′is removed from each of the bi-molded plate assemblies (e.g., by gravityor the automatic removing system 225) and cooled for an appropriateperiod of time before freezing, wrapping and packaging. The packaged,multi-layered food product 10 or 10′ can be boxed and further frozenahead of distribution to the marketplace.

From the above description of the invention, those skilled in the artwill perceive improvements, changes and modifications. For example, itshould be appreciated that the methods described herein comprise aseries of acts that may be performed in any sequence, or a subset ofacts having any sequence, to obtain the product. Such improvements,changes, and modifications are within the skill of the art and areintended to be covered by the appended claims.

1. A multi-layered food product comprising: a substantially bakedyeast-leavened dough encapsulating a filling; and a substantially bakedchemically-leavened batter layer that encapsulates thesubstantially-baked yeast-leavened dough.
 2. The multi-layered foodproduct of claim 1, wherein the weight percentage (wt-%) of said fillingis about 15% to about 60% of the total weight of said multi-layered foodproduct.
 3. The multi-layered food product of claim 1, wherein the wt-%of said yeast-leavened dough is about 10% to about 60% of the totalweight of said multi-layered food product.
 4. The multi-layered foodproduct of claim 1, wherein the wt-% of said chemically-leavened batterlayer is about 15% to about 60% of the total weight of saidmulti-layered food product.
 5. The multi-layered food product of claim1, wherein at least a portion of an outer surface of said multi-layeredfood product includes a decorative design.
 6. The multi-layered foodproduct of claim 1, having a puck-shaped configuration.
 7. Themulti-layered food product of claim 1 being configured for insertioninto a toaster having at least one square-shaped or rectangularactuatable toasting slot.
 8. A method for forming a multi-layered foodproduct comprising the following acts: substantially baking an insert ina first bi-molded plate assembly, the insert comprising a filling thatis completely enveloped by a yeast-leavened dough; placing thesubstantially baked insert into a second bi-molded plate assembly sothat the substantially baked insert is located atop a first amount of achemically-leavened batter layer; pouring a second amount of thechemically-leavened batter into the second bi-molded plate assembly sothat the second amount of the chemically-leavened batter substantiallyor completely envelops the substantially baked insert; and heating thesecond bi-molded plate assembly for a time and at a temperaturesufficient to bake the multi-layered food product.
 9. The method ofclaim 8, wherein said act of placing the substantially baked insert intoa second bi-molded plate assembly further comprises: heating the secondbi-molded plate assembly to a predetermined temperature, the secondbi-molded plate assembly comprising a receptacle member and lid member,the receptacle member and the lid member including a cavity,respectively, the cavity of the receptacle member having a volumegreater than the volume of the cavity of the lid member; and pouring thefirst amount of the chemically-leavened batter into the receptaclemember.
 10. The method of claim 9, further comprising: mating the lidmember with the receptacle member so that the cavity of each of the lidmember and the receptacle member forms a heated and sealed bakingcavity; baking the multi-layered food product for a first period oftime; and recovering the baked, multi-layered food product after asecond period of time.
 11. The method of claim 10, wherein said act ofrecovering the baked, multi-layered food product further comprises:inverting the plate assembly; heating the plate assembly for the secondperiod of time at the predetermined temperature, the second period oftime being greater than the first period of time; and separating the lidmember from the receptacle member to remove the multi-layered foodproduct from the receptacle member.
 12. The method of claim 10, whereinthe first period of time is about 10% to about 50% of the predeterminedperiod of time sufficient to form the multi-layered food product. 13.The method of claim 10, wherein the second period of time is about 50%to about 90% of the predetermined period of time sufficient to form themulti-layered food product.
 14. The method of claim 8, wherein thesecond bi-molded plate assembly includes an imprinting surface forimparting the multi-layered food product with a decorative design and/orsecurely positioning the substantially baked insert during baking.
 15. Amulti-layered food product formed according to the method of claim 8.